U.S. patent application number 15/251838 was filed with the patent office on 2018-03-01 for electromagnetic well bore robot conveyance system.
The applicant listed for this patent is General Electric Company. Invention is credited to Matthew Landon George, Mahendra Ladharam Joshi, Lily Nuryaningsih, Jeffrey Robert Potts, Dustin Michael Sharber, Qi Xuele.
Application Number | 20180058179 15/251838 |
Document ID | / |
Family ID | 59914515 |
Filed Date | 2018-03-01 |
United States Patent
Application |
20180058179 |
Kind Code |
A1 |
Nuryaningsih; Lily ; et
al. |
March 1, 2018 |
ELECTROMAGNETIC WELL BORE ROBOT CONVEYANCE SYSTEM
Abstract
A well bore robot is configured to travel along an magnetic
track element. The magnetic track element includes a plurality of
track magnets. The well bore robot includes a robot body and at
least one robot magnet. The robot magnet is disposed within the
robot body and configured to magnetically and alternatingly engage
and disengage with the track magnets. Alternating engagement and
disengagement of the robot magnet with the track magnets conveys
the well bore robot along the magnetic track element.
Inventors: |
Nuryaningsih; Lily; (Edmond,
OK) ; Sharber; Dustin Michael; (Oklahoma City,
OK) ; Joshi; Mahendra Ladharam; (Katy, TX) ;
Xuele; Qi; (Edmond, OK) ; Potts; Jeffrey Robert;
(Oklahoma City, OK) ; George; Matthew Landon;
(Oklahoma City, OK) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
General Electric Company |
Schenectady |
NY |
US |
|
|
Family ID: |
59914515 |
Appl. No.: |
15/251838 |
Filed: |
August 30, 2016 |
Current U.S.
Class: |
1/1 |
Current CPC
Class: |
Y10S 901/19 20130101;
F16L 55/30 20130101; Y10S 901/01 20130101; E21B 23/14 20130101;
B25J 9/12 20130101; B61B 13/00 20130101; F16L 2101/30 20130101;
E21B 47/01 20130101; E21B 47/00 20130101; B25J 5/02 20130101; E21B
41/00 20130101 |
International
Class: |
E21B 41/00 20060101
E21B041/00; B25J 5/02 20060101 B25J005/02; B25J 9/12 20060101
B25J009/12; E21B 47/00 20060101 E21B047/00; B61B 13/00 20060101
B61B013/00 |
Claims
1. A well bore robot configured to travel along a magnetic track
element, the magnet track element including a plurality of track
magnets, said well bore robot comprising: a robot body; and at
least one robot magnet disposed within said robot body, said at
least one robot magnet configured to magnetically and alternatingly
engage and disengage with the plurality of track magnets, wherein
alternating engagement and disengagement of said at least one robot
magnet with the plurality of track magnets conveys said well bore
robot along the magnetic track element.
2. The well bore robot in accordance with claim 1 further
comprising at least one data collection module disposed within said
robot body, said at least one data collection module configured to
collect data.
3. The well bore robot in accordance with claim 2 further
comprising at least one data storage module disposed within said
robot body and coupled in data transfer communication with said at
least one data collection module, said at least one data storage
module configured to store data collected by said at least one data
collection module.
4. The well bore robot in accordance with claim 3 further
comprising at least one data transfer brush disposed within said
robot body and coupled in data transfer communication with said at
least one data storage module, said at least one data transfer
brush configured to transfer data stored by said at least one data
storage module.
5. The well bore robot in accordance with claim 4 further
comprising at least one battery disposed within said robot body,
said at least one battery configured to power said at least one
data collection module and said at least one data storage
module.
6. The well bore robot in accordance with claim 5 further
comprising at least one control unit, said at least one control
unit comprises at least one of a chip, an integrated circuit, or a
plurality of electronic circuits configured to process data, said
at least one control unit configured to control at least one of
said least one data collection module, said at least one data
storage module, said at least one data transfer brush, or said at
least one battery.
7. The well bore robot in accordance with claim 1 further
comprising at least one wheel coupled to said robot body, said at
least one wheel configured to convey said well bore robot along the
magnetic track element.
8. The well bore robot in accordance with claim 1 further
comprising at least one retrieval flap, said at least one retrieval
flap configured to assist the plurality of track magnets and at
least one robot magnet to convey said well bore robot in a first
direction along the electromagnet track element.
9. The well bore robot in accordance with claim 1, wherein said
robot body defines at least one of a spherical shape, a cylindrical
shape, a capsule shape, a cubical shape or an annular shape.
10. The well bore robot in accordance with claim 1, wherein said
robot magnet comprises a permanent magnet and said plurality of
track magnets comprises a plurality of electromagnets.
11. The well bore robot in accordance with claim 1, wherein said
robot magnet comprises an electromagnet and said plurality of track
magnets comprises a plurality of permanent magnets.
12. A well bore robot conveyance system comprising: a magnetic
track element comprising a plurality of track magnets; and a well
bore robot comprising: a robot body; and at least one robot magnet
disposed within said robot body, said at least one robot magnet
configured to magnetically and alternatingly engage and disengage
with said plurality of track magnets, wherein alternating
engagement and disengagement of said at least one track magnet with
said plurality of track magnets conveys said well bore robot along
said magnetic track element.
13. The well bore robot conveyance system in accordance with claim
12, wherein said well bore robot further comprises at least one
data transfer brush disposed within said robot body, said at least
one data transfer brush configured to transfer data collected by
said well bore robot.
14. The well bore robot conveyance system in accordance with claim
13, wherein said electromagnet track element further comprises at
least one data transfer line configured to receive data transferred
from said at least one data transfer brush.
15. The well bore robot conveyance system in accordance with claim
14, wherein said electromagnet track element further comprises a
computer configured to receive data transferred from said at least
one data transfer line.
16. The well bore robot conveyance system in accordance with claim
13, wherein said electromagnet track element further comprises at
least one power transfer line configured to energize and
de-energize said plurality of electromagnets.
17. The well bore robot conveyance system in accordance with claim
16 further comprising a power source, said power source and said at
least one power transfer line are configured to energize and
de-energize said plurality of electromagnets.
18. The well bore robot conveyance system in accordance with claim
17, wherein said electromagnet track element further comprises a
safety latch configured to cease conveyance of said well bore robot
at a predetermined location.
19. The well bore robot conveyance system in accordance with claim
18, wherein said safety latch comprises at least one cantilever
configured in an open position when said power source and said at
least one power transfer line are not coupled in electrical
communication with said plurality of electromagnets.
20. The well bore robot conveyance system in accordance with claim
19, wherein said safety latch comprises at least one cantilever
configured in a closed position when said power source and said at
least one power transfer line are coupled in electrical
communication with said plurality of electromagnets.
21. The well bore robot conveyance system in accordance with claim
20 wherein said well bore robot further comprises at least one
brush positioned on an outer surface of said robot body, said at
least one brush configured to clean a well.
22. The well bore robot conveyance system in accordance with claim
12, wherein said robot magnet comprises a permanent magnet and said
plurality of track magnets comprises a plurality of
electromagnets.
23. The well bore robot conveyance system in accordance with claim
12, wherein said robot magnet comprises an electromagnet and said
plurality of track magnets comprises a plurality of permanent
magnets.
24. A measurement system for a cavity, said measurement system
comprising: a magnetic track element comprising a plurality of
track magnets; and a robot configured to travel along said magnetic
track element, said robot comprising: a robot body; at least one
data collection module disposed within said robot body, said data
collection module configured to collect data; and at least one
robot magnet disposed within said robot body, said at least one
robot magnet configured to magnetically and alternatingly engage
and disengage with said plurality of track magnets, wherein
alternating engagement and disengagement of said at least one robot
magnet with said plurality of track magnets conveys said robot
along said magnetic track element.
Description
BACKGROUND
[0001] The field of the invention relates generally to oil and gas
well intervention systems and, more specifically, to an
electromagnetic well bore conveyance system.
[0002] At least some known oil and gas wells require periodic well
intervention procedures. These well intervention procedures may
include well integrity inspections or equipment retrieval. At least
some known well intervention systems include wireline systems and
coiled tubing systems. Wireline systems lower repair equipment and
inspection equipment down a well with a cable or wire. Coiled
tubing systems lower repair equipment and inspection equipment down
a well with a jointless pipe. Both wireline and coiled tubing
systems require a substantial cost and a substantial amount of well
downtime.
BRIEF DESCRIPTION
[0003] In one aspect, a well bore robot is provided. The well bore
robot is configured to travel along a magnetic track element. The
magnetic track element includes a plurality of track magnets. The
well bore robot includes a robot body and at least one robot
magnet. The robot magnet is disposed within the robot body and
configured to magnetically and alternatingly engage and disengage
with the track magnets. Alternating engagement and disengagement of
the robot magnet with the track magnets conveys the well bore robot
along the magnetic track element.
[0004] In a further aspect, a well bore robot conveyance system is
provided. The well bore robot conveyance system includes a magnetic
track element and a well bore robot. The magnetic track element
includes a plurality of track magnets. The well bore robot includes
a robot body and at least one robot magnet. The robot magnet is
disposed within the robot body and configured to magnetically and
alternatingly engage and disengage with the track magnets.
Alternating engagement and disengagement of the robot magnet with
the track magnets conveys the well bore robot along the magnetic
track element.
[0005] In another aspect, a measurement system in a cavity is
provided. The measurement system includes an magnetic track element
and a robot. The magnetic track element includes a plurality of
track magnets. The robot is configured to travel along the magnetic
track element. The robot includes a robot body, at least one data
collection and data transfer module, and at least one robot magnet,
at least one power storage unit, and electronic control board. The
data collection module is disposed within the robot body and is
configured to collect data. The robot magnet is disposed within the
robot body and is configured to magnetically and alternatingly
engage and disengage with the track magnets. Alternating engagement
and disengagement of the robot magnet with the track magnets
conveys the robot along the magnetic track element.
DRAWINGS
[0006] These and other features, aspects, and advantages of the
present disclosure will become better understood when the following
detailed description is read with reference to the accompanying
drawings in which like characters represent like parts throughout
the drawings, wherein:
[0007] FIG. 1 is a schematic view of an exemplary rod pump
system;
[0008] FIG. 2 is a schematic view of well bore robot conveyance
system within a well bore shown in FIG. 1;
[0009] FIG. 3 is a schematic cut-away view of a well bore robot
shown in FIG. 2;
[0010] FIG. 4 is a schematic cut-away view of a well bore robot
shown in FIG. 1 conveys in horizontal section of a well bore;
[0011] FIG. 5 is a schematic cut-away view of a well bore shown in
FIG. 1 could be flow-assisted and launched to surface by retracting
flaps;
[0012] FIG. 6 is a cut-away schematic view of a well bore shown in
FIG. 1 with an EM track element with a safety latch in a closed
position;
[0013] FIG. 7 is a cut-away schematic view of a well bore shown in
FIG. 1 with an EM track element with a safety latch in an open
position;
[0014] FIG. 8 is a cutaway schematic view of annular well bore
robot body in a well bore shown in FIG. 1;
[0015] FIG. 9 is a top view of annular well bore robot body in a
well bore shown in FIG. 1;
[0016] FIG. 10 is a top view of a well bore robot body;
[0017] FIG. 11 is a perspective view of a well bore robot
conveyance system;
[0018] FIG. 12 is a perspective view of the well bore robot
conveyance system shown in FIG. 11 without a robot shell;
[0019] FIG. 13 is a diagram of a first polarity configuration of
electromagnets within the well bore robot conveyance system shown
in FIG. 11;
[0020] FIG. 14 is a diagram of a second polarity configuration of
electromagnets within the well bore robot conveyance system shown
in FIG. 11;
[0021] FIG. 15 is a diagram of a third polarity configuration of
electromagnets within the well bore robot conveyance system shown
in FIG. 11; and
[0022] FIG. 16 is an electrical diagram of coils within the well
bore robot conveyance system shown in FIG. 11.
[0023] Unless otherwise indicated, the drawings provided herein are
meant to illustrate features of embodiments of the disclosure.
These features are believed to be applicable in a wide variety of
systems comprising one or more embodiments of the disclosure. As
such, the drawings are not meant to include all conventional
features known by those of ordinary skill in the art to be required
for the practice of the embodiments disclosed herein.
DETAILED DESCRIPTION
[0024] In the following specification and the claims, reference
will be made to a number of terms, which shall be defined to have
the following meanings.
[0025] The singular forms "a", "an", and "the" include plural
references unless the context clearly dictates otherwise.
[0026] "Optional" or "optionally" means that the subsequently
described event or circumstance may or may not occur, and that the
description includes instances where the event occurs and instances
where it does not.
[0027] Approximating language, as used herein throughout the
specification and claims, may be applied to modify any quantitative
representation that could permissibly vary without resulting in a
change in the basic function to which it is related. Accordingly, a
value modified by a term or terms, such as "about",
"approximately", and "substantially", are not to be limited to the
precise value specified. In at least some instances, the
approximating language may correspond to the precision of an
instrument for measuring the value. Here and throughout the
specification and claims, range limitations may be combined and/or
interchanged, such ranges are identified and include all the
sub-ranges contained therein unless context or language indicates
otherwise.
[0028] As used herein, the terms "processor" and "computer", and
related terms, e.g., "processing device", "computing device", and
"controller" are not limited to just those integrated circuits
referred to in the art as a computer, but broadly refers to a
microcontroller, a microcomputer, a programmable logic controller
(PLC), an application specific integrated circuit, and other
programmable circuits, and these terms are used interchangeably
herein. In the embodiments described herein, memory may include,
but is not limited to, a computer-readable medium, such as a random
access memory (RAM), and a computer-readable non-volatile medium,
such as flash memory. Alternatively, a floppy disk, a compact
disc--read only memory (CD-ROM), a magneto-optical disk (MOD),
and/or a digital versatile disc (DVD) may also be used. Also, in
the embodiments described herein, additional input channels may be,
but are not limited to, computer peripherals associated with an
operator interface such as a mouse and a keyboard. Alternatively,
other computer peripherals may also be used that may include, for
example, but not be limited to, a scanner. Furthermore, in the
exemplary embodiment, additional output channels may include, but
not be limited to, an operator interface monitor.
[0029] As used herein, the term "non-transitory computer-readable
media" is intended to be representative of any tangible
computer-based device implemented in any method or technology for
short-term and long-term storage of information, such as,
computer-readable instructions, data structures, program modules
and sub-modules, or other data in any device. Therefore, the
methods described herein may be encoded as executable instructions
embodied in a tangible, non-transitory, computer readable medium,
including, without limitation, a storage device and/or a memory
device. Such instructions, when executed by a processor, cause the
processor to perform at least a portion of the methods described
herein. Moreover, as used herein, the term "non-transitory
computer-readable media" includes all tangible, computer-readable
media, including, without limitation, non-transitory computer
storage devices, including, without limitation, volatile and
nonvolatile media, and removable and non-removable media such as a
firmware, physical and virtual storage, CD-ROMs, DVDs, and any
other digital source such as a network or the Internet, as well as
yet to be developed digital means, with the sole exception being a
transitory, propagating signal.
[0030] The magnetic well bore robot conveyance systems described
herein facilitate a faster and more cost effective method of
intervening in an oil and gas well. The magnetic well bore robot
conveyance system includes a magnetic robot device and a magnetic
track element configured to convey the robot device down an oil and
gas well. The track element includes a plurality of magnets, either
permanent or electromagnetic or both in combination, along the
length of a wire which create a magnetic field in front of and
behind the robot device. The robot device includes at least one
magnet, either permanent or electromagnetic, which interacts with
the magnetic field of the track element. The magnetic track element
conveys and controls the descent of the robot device down an oil
and gas well by controlling magnetic polarity (south/north or
negative/positive) by alternating the direction of current flow
through the electromagnets within the magnetic track element. The
magnet within the robot body is oriented in such a way relative to
the magnetic track element as to generate a thrust force from the
interaction between the magnetic fields of the magnet within the
robot body and the magnetic track element. Alternating the
polarities of the electromagnets on the magnetic track element
causes the magnetic field in front of the robot device to move the
robot forward, while the magnetic field behind the robot device
adds more forward thrust, enabling conveyance of the robot over
long distances. Sending equipment down an oil and gas well with a
magnetic track completes well intervention in less time than
conventional inspection methods, reduces down time due to
inspections, and reduces inspection costs.
[0031] FIG. 1 is a schematic view of an exemplary rod pump system
100. In the exemplary embodiment, pump system 100 includes a beam
pump 102 with a beam 104 coupled to a polished rod string 106
adjacent a well bore 108. Well bore 108 is drilled through a
surface 110 to facilitate the extraction of production fluids
including, but not limited to, petroleum fluids and water, with and
without hard particles. As used herein, petroleum fluids refer to
mineral hydrocarbon substances such as crude oil, gas, and
combinations thereof.
[0032] Beam pump 102 is actuated by a prime mover 112, such as an
electric motor, coupled to a crank arm 114 through a gear reducer
116, such as a gear box. Gear reducer 116 converts torque produced
by prime mover 112 to a low speed but high torque output suitable
for driving the pumping oscillation of crank arm 114. Crank arm 114
is coupled to beam 104 such that rod string 106 reciprocates within
well bore 108 during operation. In alternative embodiments, beam
pump 102 is any suitable pump that facilitates reciprocating rod
string 106 as described herein. Pump system 100 further includes a
well head 118, production tubing 120 coupled to well head 118, and
a downhole pump 122 disposed at the bottom of well bore 108. Rod
string 106 is coupled to downhole pump 122 such that production
fluids are lifted towards surface 110 upon each upswing of rod
string 106. Well bore 108 requires periodic well intervention
procedures. These well intervention procedures may include well
integrity inspections or equipment retrieval, monitoring, reporting
and triggering downhole functions, measuring downhole pressure and
temperature gradients, sensing and releasing packer fluids downhole
and reporting to surface, resetting packers, controlling pressure,
determining flow rate, evaluating composition of fracturing fluid
downhole, controlling inflow control devices, dispensing chemicals
or water to aid in downhole cementing operations, equipment
retrieval, casing repair, well bore or perforation cleaning and
clearing, casing collar locating, tool conveyance, activating port
collars, activating stage cementing equipment, shifting downhole
sliding sleeves, cement bond logging, or casing caliper
logging.
[0033] FIG. 2 is a schematic view of well bore robot conveyance
system 200 which performs well integrity inspections or equipment
retrieval procedures on well bore 108. Well bore robot conveyance
system 200 includes an electromagnetic (EM) track element 202 and a
well bore robot 204. EM track element 202 is configured to convey
well bore robot 204 up and down well bore 108. EM track element 202
includes electrically conductive wire/ribbon/cable material,
similar to cables used for artificial lift equipment. Base material
of EM track element 202 is an electrically-insulating material
capable of withstanding the high temperature fluid environment
within the well bore, including polymeric materials and composites
thereof. Examples include but are not limited to epoxies,
poly(etheretherketone) (PEEK), acetal resins (e.g.,
polyoxymethylene), poly(tetra fluoroethylene) (PTFE), nitrile
rubber (NBR), hydrogenated nitrile rubber (HNBR), fluoroelastomers,
perfluoroeleastomers, and polysiloxanes such as
polydimethylsiloxane (PDMS). Reinforcing fillers for these
polymeric materials useful for this application include but are not
limited to glass fibers, carbon fibers, carbon black, silica,
alumina, and nanomaterials such as nano-silica, carbon nanotubes,
graphene, and hexagonal boron nitride. EM track element 202 further
includes a plurality of electromagnets 206, at least one data
transfer line 207, and at least one power line 208. Electromagnets
206 are positioned periodically along a length 210 of EM track
element 202 at pre-determined distances 209. In the exemplary
embodiment, distance 209 is about 1 centimeter (cm) (0.39 inches)
to about 1 meter (m) (39.4 inches). However, distance 209 may be
any length which enables well bore robot conveyance system 200 to
operate as described herein. Power line 208 is electrically coupled
to electromagnets 206.
[0034] A motorized EM track spool 212 deploys and retracts EM track
element 202. EM track element 202 and well bore robot 204 are
deployed into well bore 108 through a launching station 211
positioned upstream of a choke valve (not shown). EM track element
202 may be temporarily installed in well bore 108 or may be
permanently installed in well bore 108.
[0035] A power source 214 is electrically coupled to power line
208. Power source 214, power line 208, and data transfer line 207
transmit electrical power and control signals in the form of
timed-electrical pulses to energize and de-energize electromagnets
206. The voltage of the timed electrical pulses is about 110 volts
(V) to about 10 kilovolts (kV). However, the voltage of the timed
electrical pulses may be any voltage which enables well bore robot
conveyance system 200 to operate as described herein. The electric
current of the timed electrical pulses is about 5 amperes (A) to
about 50 A. However, the electric current of the timed electrical
pulses may be any electric current which enables well bore robot
conveyance system 200 to operate as described herein. The frequency
of the timed electrical pulses is about 60 hertz (Hz) to about 1
megahertz (MHz). However, the frequency of the timed electrical
pulses may be any frequency which enables well bore robot
conveyance system 200 to operate as described herein. The signals
are transmitted from surface 110 to the total depth (TD) 216 of
well bore 108. Additionally, the signals are transmitted from TD
216 of well bore 108 to surface 110. Thus signals may be
transmitted bi-directionally along EM track element 202 at certain
pulse frequencies. A computer 218 on surface 108 controls power
source 214, power line 208 and data transfer line 207. Computer 218
may be wirelessly coupled to EM track element 202 and power source
214 or may be coupled to EM track element 202 and power source 214
by a wire.
[0036] Well bore robot 204 includes at least one permanent magnet
220. In the exemplary embodiment, well bore robot 204 includes two
permanent magnets 220. However, well bore robot 204 may include any
number of permanent magnets 220 which enable well bore robot 204 to
operate as described herein. Energizing and de-energizing or
reversing the polarity of electromagnets 206 creates a unique
magnetic field distribution (not shown) that propel well bore robot
204 along EM track element 202. The electric current supplied to
power line 208 and electromagnets 206 is constantly alternating to
change the polarity of electromagnets 206. This change in polarity
causes the magnetic field in front of well bore robot 204 to pull
the well bore robot 204 forward, while the magnetic field behind
well bore robot 204 adds more forward thrust. In the exemplary
embodiment, the velocity of well bore robot 204 through the well
bore is about 100 feet per minute. However, the velocity of well
bore robot 204 may be any velocity which enables well bore robot
conveyance system 200 to operate as described herein.
[0037] FIG. 3 is a schematic cut-away view of well bore robot 204.
EM track element 202 further includes at least one data transfer
port 222 positioned periodically along length 210 of EM track
element 202 at pre-determined distances 224. In the exemplary
embodiment, distance 224 is about 5 millimeters (mm) (0.19 inches)
to about 1 m (39.4 inches). However, distance 224 may be any length
which enables well bore robot conveyance system 200 to operate as
described herein. Well bore robot 204 further includes a battery
226, a data storage device 228, a data transfer brush 230, at least
one sensor 232, at least one camera 234, and a plurality of control
devices 236. Data transfer brush 230 provides electrical contact
between the robot and data transfer ports 222 on data transfer line
207. Data transfer brush 230 includes an electrically conductive
contact which transfers data to an electrically conductive contact
within data transfer ports 222. Control devices 236 include a
gyroscope 238, an accelerometer 240, and a control unit 242.
Control devices 236 may include any device which enables well bore
robot conveyance system 200 to operate as described herein. Sensors
232 include well integrity sensors for well inspections, pressure
sensors, temperature sensors, viscosity sensors, accelerometers (1
axis, 2 axes, or 3 axes), conductivity sensors, magnetic
permeability sensors, flow rate sensors, density sensors, pH
meters, gamma ray detectors, acoustic sensors, x-ray or
radiographic inspection equipment, visual and infrared cameras, or
image recognition chips. Sensors 232 may include any device which
enables well bore robot conveyance system 200 to operate as
described herein. Well bore robot 204 also optionally includes a
plurality of scrapers or brushes 243 configured to remove or brush
away scale deposits, debris or other obstructions within well bore
108.
[0038] In the exemplary embodiment, battery 226 provides power to
data storage device 228, data transfer brush 230, sensors 232,
camera 234, and control devices 236. In another embodiment, well
bore robot 204 does not include battery 226. Data storage device
228, data transfer brush 230, sensors 232, camera 234, and control
devices 236 all receive power from power line 208. In another
embodiment, well bore robot 204 includes battery 226 as an
emergency source of power. In this embodiment, data storage device
228, data transfer brush 230, sensors 232, camera 234, and control
devices 236 all receive power from power line 208 during normal
operations and receive power from battery 226 when power from power
line 208 is not available.
[0039] Control unit 242 includes a chip, an integrated circuit, or
set of electronic circuits for data processing. Control unit 242 is
coupled in data transfer communication with data storage device
228, data transfer brush 230, sensors 232, camera 234, and other
control devices 236. Accelerometer 240 and gyroscope 238 provide
data to control unit 242 to track the location and direction of
well bore robot 204. In the exemplary embodiment, control unit 242
receives instructions from computer 218. In another embodiment,
control device 236 may be preprogramed and does not receive
real-time instructions from computer 218. Based on preprogrammed
instructions, control unit 242 controls data storage device 228,
data transfer brush 230, sensors 232, camera 234, and other control
devices 236 to complete a task such as a casing inspection at a
specific location. After well bore robot 204 has completed its
task, it returns to surface 110 and the data collected is
downloaded from data storage device 228.
[0040] Control unit 242 may also include wireless communications
capability. Specifically, control unit 242 may also include a
router configured to communicate with wireless networks including
WLAN, GSM, CDMA, LTE, WiMAX, or any other wireless network.
Additionally, control unit 242 may also be configured to send and
receive acoustic signals generated by piezoelectric transducers.
Control unit 242 may further be configured to send and receive
optical signals generated by fiber optic sensors. Control unit 242
may also be configured to send and receive electromagnetic
telemetry signals between sensors, transmitters, and receivers.
Control unit 242 may further be configured to send and receive
Bluetooth signals. Finally, control unit 242 may be configured to
wirelessly communicate with other well bore robots 204 within well
bore 108.
[0041] Data transfer brush 230 and data transfer port 222 include
sliding electrical contacts configured to transfer data between
them. Data transfer port 222 is coupled in data transfer
communication with data transfer line 207 which, in turn, is
coupled in data transfer communication with computer 218. Data
transfer brush 230 is coupled in data transfer communication with
data storage device 228, data transfer brush 230, sensors 232,
camera 234, control unit 242, and other control devices 236.
[0042] During operation, EM track element 202 conveys well bore
robot 204 up and down well bore 108. Sensors 232 and camera 234
collect data on the state of well bore 108. The data collected by
sensors 232 and camera 234 is stored on data storage device 228.
Data storage device 228 sends data to data transfer brush 230. Data
transfer brush 230 transfers data to data transfer port 222 once
data transfer brush 230 passes over data transfer port 222. Data
transfer port 222 transfers data to computer 218 through data
transfer line 207.
[0043] The transfer of data may also be reversed. Computer 218
transfers data to data transfer port 222 through data transfer line
207. Data transfer port 222 transfers date to data transfer brush
230 which sends data to data storage device 228, data transfer
brush 230, sensors 232, camera 234, control unit 242, and other
control devices 236.
[0044] In another operational embodiment, control unit 242 is
preprogramed to complete a task. Control unit 242 controls data
storage device 228, data transfer brush 230, sensors 232, camera
234, and other control devices 236 during this operational
embodiment. However, computer 218 still controls the movement of
well bore robot 204 by controlling the timed-electrical pulses to
energize and de-energize electromagnets 206. Once well bore robot
204 arrives at a predetermined location, control unit 242 commands
sensors 232 and camera 234 to collect data. The collected data is
stored on data storage device 228. Once well bore robot 204 returns
to surface 110, the collected data is retrieved from data storage
device 228.
[0045] In the exemplary embodiment, well bore robot 204 includes a
robot body 244 which includes a spherical shape and includes a
diameter 246. Diameter 246 is about 4 inches to about 24 inches.
However, diameter 246 may be any value which enables well bore
robot conveyance system 200 to operate as described herein. Well
bore robot 204 also includes a slot 248 configured to circumscribe
EM track element 202. Slot 248 has a similar in size and shape as
EM track element 202 with an additional gap clearance 250 around EM
track element 202 for smooth frictionless movement. Additional gap
clearance 250 has a length of about 0.16 cm (0.0625 inch) to about
0.64 cm (0.25 inch). However, additional gap clearance 250 may be
any size which enables well bore robot conveyance system 200 to
operate as described herein. Permanent magnets 220 are positioned
within slot 248 to engage with electromagnets 206. In the exemplary
embodiment, slot 248 runs through the center of well bore robot
204. However, in other embodiments (not shown), slot 248 may run
off-center through well bore robot 204.
[0046] In another embodiment, robot body 244 defines a cylindrical
shape, a capsule shape, a cubical shape, or a conical shape. Robot
body 244 may be any shape which enables well bore robot conveyance
system 200 to operate as described herein. In the exemplary
embodiment, robot body 244 is comprised of a fiber-reinforced
plastic or suitable lightweight composite material capable of
withstanding the downhole environment. Examples include but are not
limited to virgin and reinforced poly(aryletherketones) such as
PEEK, poly(etherketoneketone) (PEKK),
poly(etherketoneetherketoneketone) (PEKEKK), acetal resins (e.g.,
polyoxymethylene), poly(phenylenesulfide) (PPS), substituted
polyphenylenes, polyphenylsulfones, PTFE, and epoxy materials. In
another embodiment, robot body 244 includes light weight
dissolvable or electrochemically active materials which can degrade
when exposed to hot fresh water, saline produced water, or
activation chemicals such as acids or organic solvents. If well
bore robot 204 became irretrievable within well bore 108, robot
body 244 would dissolve when exposed to hot fresh water, saline
produced water, or activation chemicals. Such light weight
materials include magnesium alloys which can withstand 1.03
megapascal (MPa) (15,000 pounds per square inch (psi)) hydrostatic
pressure. In another embodiment, robot body 244 includes
water-dissolvable polymers such as poly(lactic acid) (PLA) and
poly(glycolic acid) (PGA) which can withstand 34.5 MPa (5,000 psi)
downhole pressure. In another embodiment, robot body 244 includes
light weight plastic or composites having sufficient buoyancy to
float in the well fluid and rise to the surface if control of well
bore robot 204 is lost. Robot body 244 may include any material
which enables well bore robot conveyance system 200 to operate as
described herein.
[0047] FIG. 4 is a schematic cut-away view of well bore 108 with a
vertical section 402 and a horizontal section 404. EM track element
202 runs through both vertical section 402 and horizontal section
404. A first well bore robot 406 is positioned within vertical
section 402 and a second well bore robot 408 is positioned within
horizontal section 404. First well bore robot 406 includes at least
one wheel 410 configured to convey first well bore robots 406 along
EM track element 202. Wheel 410 assists first well bore robot 406
within vertical section 402 by rolling along the side of well bore
108 reducing the friction against well bore 108. Wheel 410 allows
first well bore robot 406 to move in a horizontal direction 414
along horizontal section 404 within well bore 108. Second well bore
robot 408 includes track element 412 configured to convey second
well bore robots 408 along EM track element 202. Track element 412
assists second well bore robots 408 within vertical section 402 by
rolling along the side of well bore 108 reducing the friction
against well bore 108. Track element 412 allows second well bore
robots 408 to move in horizontal direction 414 along horizontal
section 404 within well bore 108.
[0048] FIG. 5 is a cut-away schematic view of well bore 108 with a
well bore robot 500. Well bore robot 500 includes a plurality of
flaps 502 which are stored in a non-deployed configuration (not
shown) during normal operations. Flaps 502 are attached to well
bore robot 500 and a plurality of gaps 504 are defined between
flaps 502. During off-normal operations, such as when well bore
robot 500 becomes stuck in well bore 108, well fluids are allowed
to flow through well bore 108 in a vertical direction 506. Flaps
502 are deployed into the flow of well fluids to assist with
retrieval of well bore robot 500. The well fluids propel well bore
robot 500 to surface 110 (shown in FIG. 1). Gaps 504 allow well
fluids to flow past well bore robot 500. In the exemplary
embodiment, well bore robot 500 includes four flaps 502. However,
well bore robot 500 may include any number of flaps 502 which
enables well bore robot conveyance system 200 to operate as
described herein.
[0049] FIG. 6 is a cut-away schematic view of well bore 108 with an
EM track element 600 with a safety latch 602 in a closed position.
FIG. 7 is a cut-away schematic view of well bore 108 with EM track
element 600 with safety latch 602 in an open position. Safety latch
602 includes at least one cantilever 604 coupled to EM track
element 600 at a pivot point 606. Pivot point 606 allows cantilever
604 to pivot between a closed position and an open position.
Cantilever 604 pivots to a closed position during normal operations
or when EM track element 600 is coupled to power source 214.
Cantilever 604 is parallel to EM track element 600 and allows well
bore robot 204 to pass when in a closed position. Cantilever 604
pivots to an open position during off-normal operations or when EM
track element 600 is not coupled to power source 214. Cantilever
604 is perpendicular to EM track element 600 and does not allow
well bore robot 204 to move when in an open position. Safety latch
602 prevents well bore robot 204 from descending further into well
bore 108 when power from power source 214 has been lost. Once
safety latch 602 has stopped the descent of well bore robot 204, EM
track element 600 is retracted to surface 110 and well bore robot
204 is retrieved. If power is restored to EM track element 600,
well bore robot 204 will rise to allow cantilever 604 to pivot into
a closed position and well bore robot 204 continues to safely
descend past safety latch 602.
[0050] FIG. 8 is a cutaway schematic view of a robot body 700 in a
well bore 701. FIG. 9 is a top view of robot body 700 in well bore
701. FIG.10 is a top view of robot body 700. Well bore 701 includes
a production tube 702 positioned within well bore 701 and
configured to channel production fluids (oil, water, and gas) to
surface 110. Robot body 244 (shown in FIGS. 2-6) is unable to
descend well bore 701 because production tube 702 interferes with
the descent of the spherically shaped robot body 244. As such,
robot body 700 defines a torus shape which circumscribes production
tube 702 and allows robot body 700 to descend well bore 701. Robot
body 700 includes a first half 704 and a second half 706. First and
second halves 704 and 706 are coupled together around production
tube 702 at launch station 211. EM track element 202 runs through
the center of robot body 700 on one side of production tube 702.
Robot body 700 operates in a similar manner as well bore robot
204.
[0051] FIG. 11 is a perspective view of well bore robot conveyance
system 300 which performs well integrity inspections or equipment
retrieval procedures on well bore 108. Well bore robot conveyance
system 300 is similar to well bore robot conveyance system 200
except that the well bore robot contains electromagnets while the
track consists of permanent magnets distributed along its length.
Well bore robot conveyance system 300 includes a magnetic track
element 302 and an electromagnetic (EM) well bore robot 304.
Magnetic track element 302 is configured to convey EM well bore
robot 304 up and down well bore 108. Magnetic track element 302
includes all of the attributes of EM track element 202 except for
the arrangement of the magnets described below. Similarly, EM well
bore robot 304 includes all of the attributes of well bore robot
204 except for the arrangement of the magnets described below. EM
well bore robot 304 includes a shell 305. In the exemplary
embodiment, shell 305 defines a cylindrical shape. In another
embodiment, shell 305 defines a capsule shape, a cubical shape, or
a conical shape. Shell 305 may be any shape which enables well bore
robot conveyance system 300 to operate as described herein.
[0052] Magnetic track element 302 further includes a plurality of
permanent magnets 306, at least one data transfer line 307, and at
least one power line 308. Permanent magnets 306 are positioned
periodically along a length 310 of magnetic track element 302 at
pre-determined distances 309. Each permanent magnet 306 consists of
a north pole 312 and south pole 314. Permanent magnets 306 are
positioned such that north poles 312 and south poles 314 alternate
along the length of the magnetic track element 302.
[0053] FIG. 12 is a perspective view of well bore robot conveyance
system 300 without shell 305. EM well bore robot 304 includes a
magnetic sled 316 which includes a plurality of electromagnets 318
and a control board 320. In the exemplary embodiment, magnetic sled
316 includes three electromagnets 318. However, magnetic sled 316
may include any number of electromagnets 318 which enables EM well
bore robot 304 to operate as described herein. Each electromagnet
318 includes a coil 322 and a core 324. In the exemplary
embodiment, coils 322 include copper coils. However, coils 322 may
include any material which enables EM well bore robot 304 to
operate as described herein. In the exemplary embodiment, cores 324
include iron cores. However, cores 324 may include any material
which enables EM well bore robot 304 to operate as described
herein. Each coil 322 is wrapped around a respective core 324. Each
coil 322 is electrically coupled to power line 308. Control board
320 controls the polarity of electromagnets 318.
[0054] Energizing and de-energizing or reversing the polarity of
electromagnets 318 creates a unique system of magnetic fields (not
shown) that convey EM well bore robot 304 along magnetic track
element 302. The electric current supplied to power line 308 and
electromagnets 318 is constantly alternating to change the polarity
of electromagnets 318. This change in polarity causes the magnetic
field to pull the EM well bore robot 304 forward. In the exemplary
embodiment, the velocity of EM well bore robot 304 is about 100
feet per minute. However, the velocity of EM well bore robot 304
may be any velocity which enables well bore robot conveyance system
300 to operate as described herein.
[0055] FIG. 13 is a perspective view, left side view, and right
side view of a first polarity configuration 332 of electromagnets
318 when EM well bore robot 304 travels along magnetic track
element 302. Right side view of FIG. 13 is taken along section A-A
and left side view of FIG. 13 is taken along section B-B. FIG. 14
is a perspective view, left side view, and right side view of a
second polarity configuration 334 of electromagnets 318 when EM
well bore robot 304 travels along magnetic track element 302. Right
side view of FIG. 14 is taken along section A-A and left side view
of FIG. 14 is taken along section B-B. FIG. 15 is a perspective
view, left side view, and right side view of a third polarity
configuration 336 of electromagnets 318 when EM well bore robot 304
travels along magnetic track element 302. Right side view of FIG.
15 is taken along section A-A and left side view of FIG. 15 is
taken along section B-B. In the exemplary embodiment,
electromagnets 318 include three electromagnets 326, 328, and 330
and three polarity configurations 332, 334, and 336. In FIGS. 13,
14, and 15, magnetic north polarity is indicated by crosshatching,
magnetic south polarity is indicated by dot, and off or no magnetic
polarity is indicated by no shading. In first polarity
configuration 332 shown in FIG. 13, a first electromagnet 326 is
configured with a given north-south polarity configuration, a
second electromagnet 328 is configured with an opposite polarity
configuration to first electromagnet 326, and a third electromagnet
330 is off with no magnetic polarity. Electromagnets 318 then
change to second polarity configuration 334 shown in FIG. 14. In
second polarity configuration 334 first electromagnet 326 maintains
its polarity arrangement from configuration 332, second
electromagnet 328 is off, and a third electromagnet 330 is
configured to have opposite polarity to first electromagnet 326.
Electromagnets 318 then change to third polarity configuration 336
shown in FIG. 15. In the third polarity configuration 336 the first
electromagnet 326 is off, a second electromagnet 328 is configured
with the same polarity as electromagnet 326 in previous
configuration 334, and a third electromagnet 330 is configured with
the opposite polarity arrangement of second electromagnet 328.
Finally, the cycle repeats and electromagnets 318 return to first
polarity configuration 332 shown in FIG. 13. Alternating the
polarity configuration between first, second, and third polarity
configurations 332, 334, and 336 causes the magnetic field to
convey the EM well bore robot 304 forward along the magnetic track
element 302.
[0056] FIG. 16 is an electrical diagram of coils 322. EM well bore
robot 304 includes a plurality of relays 338. Each relay 338 is
electrically coupled to controller 320, a coil 322, and power line
308. Power line 308 provides electrical power to each coil 322
through a respective relay 338. Each coil is electrically coupled
to two relays 338. For coil 322 to produce a magnetic field with a
given polarity configuration, one of the relays 338 provides
current to coil 322. When coil 322 requires an opposite polarity
configuration, the other relay 338 reverses the current direction
within coil 322. When coil 322 requires no magnetic field, neither
relay 338 provides power to coil 322.
[0057] Well bore robot conveyance systems 200, 300, and 700 are not
limited to obtain measurements in well bores 108. Rather well bore
robot conveyance systems 200, 300, and 700 may be used to obtain
data on any cavity, such as, but not limited to, sewer drains,
pipes, pipes in industrial facilities, air ducts, piping in
industrial machines, and any cavity which may require inspection
and maintenance.
[0058] The above described well bore robot conveyance systems
facilitate a faster and more cost effective method of inspecting an
oil and gas well. Specifically, the well bore robot conveyance
systems convey repair and inspection equipment down an oil and gas
well using an electromagnetic track. More specifically, robot
devices, which include repair and inspection equipment, are
conveyed down the electromagnetic track by controlling the polarity
of the electromagnets within either the track or the robot. Sending
equipment down an oil and gas well with an electromagnetic track
completes well inspections in less time than conventional
inspection methods, reduces down time due to inspections, and
reduces inspection costs.
[0059] An exemplary technical effect of the methods, systems, and
assembly described herein includes at least one of: (a) sending a
robot device down a cavity with an electromagnetic track; (b)
decreasing the intervening time of the cavity; (c) reducing the
downtime of equipment including cavities; and (d) reducing the cost
of an inspection of equipment including cavities.
[0060] Exemplary embodiments of methods, systems, and apparatus for
electromagnetic well bore robot conveyance systems are not limited
to the specific embodiments described herein, but rather,
components of systems and/or steps of the methods may be utilized
independently and separately from other components and/or steps
described herein. For example, the methods, systems, and apparatus
may also be used in combination with other systems having cavities
such as pipes and sewers, and the associated methods, and are not
limited to practice with only the systems and methods as described
herein. Rather, the exemplary embodiment can be implemented and
utilized in connection with many other applications, equipment, and
systems that may benefit from cavity inspection and repair.
[0061] Although specific features of various embodiments of the
disclosure may be shown in some drawings and not in others, this is
for convenience only. In accordance with the principles of the
disclosure, any feature of a drawing may be referenced and/or
claimed in combination with any feature of any other drawing.
[0062] Some embodiments involve the use of one or more electronic
or computing devices. Such devices typically include a processor,
processing device, or controller, such as a general purpose central
processing unit (CPU), a graphics processing unit (GPU), a
microcontroller, a reduced instruction set computer (RISC)
processor, an application specific integrated circuit (ASIC), a
programmable logic circuit (PLC), a field programmable gate array
(FPGA), a digital signal processing (DSP) device, and/or any other
circuit or processing device capable of executing the functions
described herein. The methods described herein may be encoded as
executable instructions embodied in a computer readable medium,
including, without limitation, a storage device and/or a memory
device. Such instructions, when executed by a processing device,
cause the processing device to perform at least a portion of the
methods described herein. The above examples are exemplary only,
and thus are not intended to limit in any way the definition and/or
meaning of the term processor and processing device.
[0063] This written description uses examples to disclose the
embodiments, including the best mode, and also to enable any person
skilled in the art to practice the embodiments, including making
and using any devices or systems and performing any incorporated
methods. The patentable scope of the disclosure is defined by the
claims, and may include other examples that occur to those skilled
in the art. Such other examples are intended to be within the scope
of the claims if they have structural elements that do not differ
from the literal language of the claims, or if they include
equivalent structural elements with insubstantial differences from
the literal language of the claims.
* * * * *